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Troubleshooting Guide | Order Mover | 048483-1  
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Revision table  
Revision  
Date  
Author  
Modifications  
1
Initial revision  
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5595-A  
5595-B  
/
5595-C  
5595-D  
24911-A  
/
5595-E  
9299-A  
9299-B  
Electrical  
Drawings  
Technical  
File  
Automation  
Manual  
Localization  
Spare Parts  
Installation  
procedure  
An Order Mover uses the following interfaces to work with the rest of the Skypod System:  
380V power distribution from the Skypod System power bus  
Ethernet connection from the associated Picking Station (note: all Order Mover PLCs have the  
same IP 10.0.0.20 and thus are on a different subnet than the rest of the Skypod System. The  
Picking Station acts as a gateway to route the communication between Astar and the Order  
Mover)  
Dual-channel dry contacts to get the Skypod System safety information (note: the PLC only  
receives the information, it’s not part of the safety ASI loop).  
Dry contacts to interface with other Order Movers or an external system (Ready to Receive /  
Ready to Send signals).  
SEW cards are daisy-chained on a few branches that run along the frame :  
One under the alveolus  
One for the output buffer  
One for the input buffer  
One on each side of the fixed drain (+ variable drain if any)  
The full structure can be found in the Technical File and Electrical Drawings available for each revision.  
In case of failure of one particular SEW card, all cards plugged after that one in the chain can be seen  
as disconnected even if they are healthy.  
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So considering the example below, if cards A10-1-02, 03, 04 and 05 are seen as disconnected on the  
Maintenance Page, the problem is likely coming from A10-1-05 or from the connection between A10-  
1-05 and A10-1-07.  
Disconnected  
Check cards and  
connections  
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SEW cards are powered by two ASI lines : the yellow one is the logic supply and is permanent, the  
black one is the power supply and is cut when an emergency stop is triggered.  
SEW can be either vampirized directly on ASI lines or be powered by a derivation module.  
On derivation modules, four LEDs in total indicate the logic and power voltage presence. When the  
safety is active, all four LEDs shall be lit, otherwise it indicates either a power supply fault or a broken  
fuse.  
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For the wiring and logic of dry contacts, refer to the part §6.3 and subsequent parts of the document  
018642-2 Order Mover Integration Manual.  
For dry contacts debugging, a “Dry Contacts Test Mode” is available on the Maintenance Page :  
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For each interface, the status of Ready to Send and Ready to Receive signal are shown (a red arrow  
for a False value and green arrow for a True value).  
Signal logic on the Order Mover side :  
Ready to Send is True when a load is present on the last conveyor step and no emergency stop  
is applied on the system  
Ready to Receive is True when the Ready to Send signal from the external system is True, the  
first conveyor step is available (no detection on the cell), the motor is running and no  
emergency stop is applied on the system  
The Order Mover expects the Ready to Receive signal from the external system to switch to  
False between two consecutive outbound loads (to prevent load collisions in the case of  
signal latency)  
Bypass is a mode where the Order Mover will automatically convey loads towards the next/previous  
one, without requesting decisions from Astar and therefore without entering the Preparation  
Alveolus.  
When switching to Bypass mode, any loads already present in alveolus or input buffer will be sent  
towards the left exit.  
This mode is intended to keep using the next Order Movers in the line in case of :  
Failure on the Picking Station that prevents any communication between Astar and the Order  
Mover  
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Hardware failure in the buffers or in the preparation alveolus that prevents using the current  
Order Mover for preparation.  
The Configuration panel can be accessed by clicking on the Gearicon on the left of the maintenance  
page. The following parameters can be accessed, according to the Order Mover revision :  
SCS is in mono-barcode configuration : check if this preparation line uses Preparation  
Containers which have only one label on one large face.  
IO conveyor is present : if this Order Mover has a Left or Right IO drain (parts  
017814/017842/030037/030039) alone or in addition to a variable drain (parts  
020139/030035)  
Intermediate conveyor length : number of steps of the Variable Drain (excluding IO drain if  
any : if there is an IO drain alone, leave this value to 0). Tip : count the number of motor rollers  
on the variable part.  
Intermediate conveyor position : self-explanatory :)  
After any modification, a hard reboot of the Order Mover shall be performed.  
How to determine the intermediate conveyor length :  
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The simplest way is to count the number of roller motors on the variable drain part.  
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Various status light can indicate if the PLC is running or not.  
First, make sure the switch is on RUN position:  
Make sure all PWR LEDs are lit. If not, it may indicate:  
a power supply problem (check all circuit breakers and CE1 power supply and its submodules).  
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E1 to E7 cards may not be plugged correctly into the rail.  
Then check the main status light, the green LED should be lit. If an orange or red LED is lit, it means  
the PLC is in error.  
Direct connection test :  
Plug an Ethernet cable directly from the PLC to your computer.  
Set your network parameters as:  
IP : 10.0.0.x (x != 20)  
Subnet mask : 255.255.255.0  
Then open a terminal in Linux or WSL and type :  
Both commands shall output a success message.  
Belts are subject to wear, which may result in a lack of adherence and thus to uneven speed between  
rollers.  
Creaking noises during operation often indicate worn out belts.  
When doing a visual inspection, those signs indicate worn out belts:  
A matte and porous rubber aspect (when new, the rubber surface is bright)  
The presence of rubber dust  
Also, when turning a roller by hand while blocking the adjacent one, it should not be “too easy” to do  
so, otherwise the belt has to be replaced.  
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Cells are optical components and thus are sensitive to excessive dust or presence of foreign objects.  
Also, improper mounting will reduce the cells detection performance.  
Use Profinet V3.0.0.5 or above to draw a network map of the equipment inside the Order Mover (SEW  
cards, scanners…).  
Download link : Dropbox (EXOTEC ENT)\E - Maintain it\1 - Gestion\6 - Procédures\009033 - How to  
configure SEW board\proneta_3_0_0_5.zip  
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It is advised to connect on the A10_SW1 (under the Preparation Alveolus) so that the network map  
shape will be consistent with the drawings in the Technical File.  
In Control Tower, go to the Preparation Container view and filter on non-empty value for “NodeId”  
field. Doing so will display all Preparation Containers and their known position in database :  
Alternatively, this query can be executed in a SQL client :  
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SELECT  
pc.pk, pc.barcode,  
COALESCE(st.name, ap.name) AS pename,  
cn.type,  
pc.lastdecisiondate  
FROM preparationcontainer AS pc  
LEFT JOIN conveyoredge AS ce  
ON ce.pk = pc.conveyoredgefk  
LEFT JOIN conveyornode AS cn  
ON (cn.pk = pc.conveyornodefk OR cn.pk = ce.targetnodefk)  
JOIN ordermover AS om ON om.pk = cn.ordermoverfk  
JOIN skypodconveyingsystemorder AS ord ON ord.ordermoverfk = om.pk  
LEFT JOIN station AS st  
ON (st.pk = om.preparationelementfk AND om.preparationelementtype =  
'STATION')  
LEFT JOIN autopicker AS ap  
ON (ap.pk = om.preparationelementfk AND om.preparationelementtype =  
'AUTOPICKER')  
WHERE  
(pc.conveyoredgefk IS NOT NULL OR pc.conveyornodefk IS NOT NULL)  
ORDER BY ord.index ASC, cn.type ASC, pc.lastdecisiondate DESC;  
In case of discrepancy between Preparation Containers position in database and actual position on  
conveyors, remove the containers from the conveyors and put them in quarantine using the Picking  
Station HMI or the “Action” menu :  
Possible cause : PLC not operational  
Possible cause : connection issue  
What to check : the Ethernet cable between the Picking Station and the Order Mover shall be plugged,  
the activity LED shall be blinking.  
Also, check that the Ethernet cable coming from the Order Mover Ethernet port goes directly to the  
LAN2 port of the Picking Station computer.  
Resolution : set the cabling in accordance with the Picking Station electrical diagrams.  
Possible cause : Picking Station computer misconfiguration  
What to check : From the Skypod Maintenance network, the following commands shall output a  
success message (with xxxx replaced by the actual station name) :  
Resolution : request assistance in the #support_infra Slack channel  
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Possible cause (during commissioning) : wrong Ethernet cabling  
What to check : at interfaces between two Order Movers, only dry contacts shall be connected.  
Otherwise it will create network collisions and PLC wont boot or create plenty of Device  
Disconnectederrors.  
Left Variable and/or  
IO Drain  
Right  
Variable  
and/or IO Drain  
Resolution : Refer to the installation procedure and redo step-by-step the Cabling part.  
Possible cause : barcode printing issue  
What to check : use a barcode verifier to check if barcodes are at least of grade C. If not, reading rate  
is not guaranteed.  
Possible cause : scanners not correctly setup  
What to check : refer to 019843 Order Mover Automation Description to check if the setup matches  
the label position on Preparation Containers used of this line.  
Possible cause : scanners swapped or wrong addressing  
What to check : check on the scanner screen if the device name matches the name expected by the  
PLC.  
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Resolution : use PRONETA to setup proper device address (or physically swap the scanners).  
Possible cause : connection issue  
What to check : check on the Maintenance Page if there is any “Device Disconnected” error. Check on  
the scanner if the “NET” status LED is on.  
Resolution : check Ethernet connection and the switch status in COM cabinet  
Possible cause : hardware failure  
What to check : check on the Maintenance Page if there is any “Device in Fault” error. Check on the  
scanner if the “STATUS” LED is red or powered off.  
Resolution : replace the scanner. Don’t forget to assign a device name to the new part using PRONETA.  
Possible cause : power supply fault  
What to check : Scanners are supplied by a cable vampirized on the yellow ASI cable. If only the scanner  
is not powered, the fault may be due to the cable or connectors. If several other equipment are  
powered off in the same zone, check the status of TR2, TR3 power supplies and circuit breakers in the  
A10 cabinet under the preparation alveolus.  
Possible cause : in Semi-finished, no doable Preparation Request  
What to check : In Semi-finished mode, Preparation Containers only come into alveolus when the  
Picking Station or Skypicker is in Preparation Mode, a category is selected and there are doable  
Preparation Requests in queue.  
Check in the Preparation Request view of Control Tower that there are Requests with doable = True  
status = ‘NOT_FINISHED’ and a corresponding Category.  
Possible cause : activation switch  
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What to check : if the activation switch is off, it will prevent all movements on the dispatch area. This  
switch is also monitored on the Maintenance Page :  
Resolution : set the Activation Switch to 1.  
Possible cause : Preparation Containers already there for Astar  
Possible cause : inductive sensor issue  
What to check : there are two inductive sensors on each transfer table (Cp10xxxRlx for the rollers  
position and Cp10xxxBde for the belts position). Under the transfer table, check that the two M12  
connectors are firmly connected. In a valid position, one of the two sensors should have its status LED  
powered on.  
In the maintenance page, click on the transfer table and check if the “Direction” value is either “x” or  
y”. In manual mode, it is possible to select a state as “Direction Manual” and check if the transfer  
table behaves accordingly :  
If the transfer table switches position over and over without staying in a stable position, the issue is  
probably linked to the sensors or their cabling.  
Resolution : If a hardware issue is detected, the up/down mechanical assembly should be replaced.  
Possible cause : mechanical failure  
What to check : in manual mode, try to switch the position as shown above. If the transfer table does  
not react, the up/down mechanism may be stuck. Additionally, an error such as “Motor Fault” on the  
Maintenance Page may indicate a hardware failure.  
For motor cards powered by a derivation module, check that all LEDs are lit when the safety is active.  
If not, it indicates that a fuse broke down, likely because of a motor overload due to a mechanical  
issue.  
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Resolution : The transfer table sub-assembly shall be replaced in case of mechanical issue.  
Additionally, if the derivation module fuses broke down, the module has to be replaced.  
Possible cause : SEW card issue  
What to check : On the Maintenance Page, look for errors such as “Device in Fault – A10-x-xx” or  
Device Disconnected A10-x-xx”.  
Possible cause : Bypass activated  
What to check : if the Bypass is activated, loads will cross the Order Mover without requesting a  
decision from Astar.  
Resolution : set the Bypass switch to 0.  
Possible cause : Non-detection on cells  
What to check : check that all cells around transfer tables are correctly mounted and detecting loads.  
Pay particular attention to those clipped on plastic holders (in yellow on the screenshot below).  
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Possible cause : wrong configuration regarding intermediate drain size  
What to check : refer to Maintenance Page  
Resolution : set the correct configuration on the Maintenance Page. Do a hard reboot of the OM after  
a configuration change.  
Possible cause : cabling issue  
What to check : execute the 034874-2 Inspection Electrical Cabinet COM procedure to look for  
cabling errors or continuity issue  
Resolution : open a Quality ticket and follow their instructions  
Possible cause : wrong sequence on Ready to Receive / Ready to Send signals  
What to check : go to the dedicated section or Order Mover Integration Manual for detailed  
description.  
Possible cause : preparation containers out of specifications  
preparation containers meet the specifications.  
Resolution : discuss it with the Project Manager.  
Possible cause : issue with conveyors alignment or flatness  
What to check : refer to the Flatness & General checks of the installation procedure  
Resolution : correct the mechanical installation  
Possible cause : sideguards issue  
What to check : if sideguards are not aligned properly, loads may be blocked  
Resolution : correct the sideguards positions  
Possible cause : worn-out belts  
What to check : refer to the dedicated part  
Resolution : replace worn-out belts  
Possible cause : uneven speed between OM and external system  
What to check : with a tachometer, check that speeds of both system at interface are equal.  
Resolution : report the issue to the Project Manager  
Possible cause : preparation containers are too dark to be correctly detected  
What to check : 027988 Order Mover Fulfillment Containers Specification forbids dark totes because  
detection on roller sensors is not reliable.  
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To test if containers are detected, it can be placed above a cell and check if the cell is active on the  
Maintenance Page. Also the cell shall remain active even if the container is lifted of a few centimeters  
above the conveyor.  
Possible cause : sensor malfunction  
What to check : check that all sensors in the area are clean and functioning well (see Cells).  
Resolution : clean the cells and replace in case of malfunction  
Possible cause : motor malfunction  
What to check : on the Maintenance Page, switch to manual mode, make the motors turn in a given  
direction and observe if they are actually moving. Look for any error related to motors or SEW cards  
in the Errors tab.  
Resolution : replace any defective motor or SEW card  
Possible cause : light issue  
What to check : on the Maintenance Page, try to switch the light state (Off/On/Blinking) to activate it  
manually.  
Resolution : replace the light if defective  
Possible cause : presence sensor issue  
What to check : place a container on the Oversize step and check on the Maintenance Page if the  
crosswise sensor (C10142a) is active.  
Resolution : replace the sensor if defective  
Possible cause : Tim100 configuration  
Possible cause : button malfunction  
Possible cause : Tim100 configuration  
Possible cause : Tim100 not plugged  
Possible cause : switch malfunction  
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Possible cause : hardware issue with lights or buttons  
Possible cause : cabling issue  
Possible cause : Order Movers not properly declared in the graph  
Possible cause : scanning issue on Picking Station  
Possible cause : something abnormal under the frame  
What to check : look under the Order Mover to see if these is any object that hinders the robot  
clearance (loose cable…).  
Resolution : make sure all elements are properly fastened  
Possible cause : incorrect ground clearance  
What to check : measure that the conveying height on the SCS line matches the purchase order. Also  
check that the conveying height is consistent with the Skypod Tote height (conveying height 920mm  
for 220 and 320mm totes, 1050 for 420mm totes).  
The issue may have different causes according to the spot where Preparation Containers are blocked.  
It may be :  
On a Decision Point  
At the interface with another OM or the external system  
At tackers (stoppers)  
Somewhere else (straight conveyor block or transfer table)  
Add picture  
Possible cause : no connection between the Picking Station and the OM  
Resolution :  
Check the connection status on the Picking Station Screen, it should display “Order Mover OK”.  
If it displays “Order Mover KO”, check the Ethernet connection between the back of the Order Mover  
and the Order Mover slot of the Station, and between the back of the OM and the PLC.  
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Possible cause : Order Mover not (correctly) defined in the Project Builder  
Check in the Project Builder if the Order Mover is correctly associated with the preparation element  
(Picking Station or Skypicker) and all their order in correct (consecutive numbers starting at 0).  
Possible cause : incorrect endpoint  
Resolution : check the endpoint in the Order Mover view of Control Tower. It shall be  
opc.tcp://station-xxxx:4840/ (or left blank).  
Possible cause : communication issue between Astar and the Order Mover.  
Resolution : restarting Astar will likely solve the issue (hint : it is a good practice to set a Fast Stop  
before proceeding).  
Possible cause : hardware issue on the inductive position sensors.  
What to check : under the stopper, check that the two M12 connectors Cp10xxxah (high end sensor)  
and Cp10xxxab (low end sensor) are firmly connected. In a valid position, one of the two sensors  
should have its status LED powered on.  
In the maintenance page, click on the Stopper and check if the “Direction” value is either “Up” or  
“Down”. In manual mode, it is possible to select a state as “Direction Manual” and check if the stopper  
behaves accordingly :  
Resolution : If a hardware issue is detected, the whole stopper assembly should be replaced.  
Possible cause : mechanical or roller motor issue.  
What to check : check if the stopper can move in manual mode as above.  
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Resolution : If a hardware issue is detected, the whole stopper assembly should be replaced.  
Possible cause : issue with associated SEW card  
Resolution : refer to the dedicated part  
Possible cause : ghost tote  
What to check : on the Maintenance Page, check if totes are memorized by the PLC but sensors not  
activated.  
Insert screenshot  
Resolution : perform a “CLEAR” on downstream conveyor steps.  
Possible cause : roller motor or SEW cards issue  
Possible cause : logic supply failure  
What to check :  
On the Maintenance Page, look for “Device disconnected” errors.  
Check on the SEW cards if any indicator LEDs are lit.  
Resolution :  
Check that all circuit breakers are closed in the main electrical cabinet.  
Check all connectors on the yellow ASI line are connected where they should be.  
Check the power supply in the C11 cabinet for any fault.  
Possible cause : power supply failure  
What to check :  
Switch to manual mode and check if roller motors on downstream conveyor steps can move. If several  
adjacent steps cannot move, it may indicate a power supply failure.  
Look for “Power supply out of range” errors on the Maintenance Page.  
Resolution :  
Check that all circuit breakers are closed in the main electrical cabinet.  
Check that all 380V (black round) cables are connected where they should be.  
Use the Technical File to identify which CAR cabinet is supplying the faulty zone.  
Inspect this CAR cabinet (under the conveyor frame) and the black ASI wire coming from this cabinet.  
Replace the power supply in the CAR cabinet if faulty. Replace the black ASI wire if damaged.  
Possible cause : detection cells problem  
What to check : on the Maintenance Page, check if cells are activated or in error without any tote  
present, or if any cell is not activated while there is a tote present.  
Check if cells are clean and well aligned (for cells on clip holders). Add screenshot  
Check the cells status feedback on the maintenance page when placing your hand above.  
Resolution : replace a cell which does not behave properly.  
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